Simulation of Mechanical and Thermal Loads and Microtexturing of Ceramic Cutting Inserts in Turning a Nickel-Based Alloy

This paper is devoted to the problem of wear resistance in square Si3N4 ceramic cutting inserts, which exhibit high hardness and strength, combination with brittleness, machining super alloys (e.g., a nickel-based alloy Inconel 718 type) for aviation purposes, when subjected increased mechanical thermal loads. Microtextures were proposed reduce intensity contact loads on pad between edge workpiece. The simulation demonstrated superior ability faces preformed microgrooves (125 µm width) compared microwells (ø100 µm). tense state was 4.97 times less, there 2.96 fewer deformations. It shown that they hamper development fields at 900 °C. Two types microtextures (210 µm-wide 80 diameter) produced rake inserts via an innovative integrated approach (the electrical discharge dielectrics using multifunctional TiO2-assisted powder), conductive wear-resistant TiN coating deposited magnetron vacuum plasma sputtering (95%N2/5%Ar). failure criterion turning 400 µm. An increase 30% tool demonstrated.